Disconnect device

ABSTRACT

A disconnect assembly includes a head coupler portion and a tool coupler portion. The head coupler portion includes: a threaded portion on a first part of an exterior surface to connect to a wedge frame, a longitudinal bore, a rod configured to slide longitudinally within the longitudinal bore, and a set of annular protrusions on a second part of the exterior surface. The tool coupler portion includes: a threaded bore configured to mechanically attach the tool coupler portion to the tool, and a channel to receive a head coupler portion. The channel includes a set of grooves corresponding to the set of annular protrusions on the head coupler portion. When the head coupler portion is connected to the tool coupler portion, a ram from the hydraulic tool engages the rod to apply force to an object in the wedge frame.

RELATED APPLICATION

This application claims priority under 35 U.S.C. §119, based on U.S.Provisional Patent Application No. 61/584,360, filed Jan. 9, 2012, thedisclosure of which is hereby incorporated by reference herein.

BACKGROUND INFORMATION

In electrical power systems it is occasionally necessary to tap into anelectrical power line. One known system for tapping into an electricalpower line is to use a tap connector for electrically connecting amainline electrical cable to an end of a tap line electrical cable. Onesuch tap connector, referred to as a wedge connector, includes aconductive C-shaped member and a wedge. To install the wedge connector,two cables are positioned at opposite sides of the C-shaped member andthe wedge is driven between the two cables. Insertion of the wedgeforces the two cables against the C-shaped member to provide a secureconductive contact.

Wedge connectors have conventionally been installed usingexplosively-driven connecting tools to drive the wedge. More recently,battery-operated hydraulic tools have been introduced to install wedgeconnectors.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides an isometric view of a hydraulic tool in which apparatusand methods described herein may be implemented;

FIG. 2 provides a view of the hydraulic tool of FIG. 1 including adisconnect assembly according to an implementation described herein;

FIG. 3 provides a cross sectional view of a head coupler of thedisconnect assembly of FIG. 2;

FIG. 4 provides a cross sectional view of a tool coupler of thedisconnect assembly of FIG. 2;

FIG. 5 provides a cross sectional view of the disconnect assembly ofFIG. 2 in a coupled configuration;

FIG. 6 provides a side view of the disconnect assembly of FIG. 2, in acoupled configuration, installed between the hydraulic tool and wedgeframe of FIG. 1;

FIG. 7 is a flowchart of an exemplary process for installing a wedgeconnector using a hydraulic installation tool and a disconnect assembly,according to an implementation described herein; and

FIGS. 8A-8C provide isometric views of a wedge connector installationprocess according to an implementation described herein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The following detailed description refers to the accompanying drawings.The same reference numbers in different drawings may identify the sameor similar elements. Also, the following detailed description does notlimit the invention.

Battery-operated hydraulic tools for installing wedge connectors provideseveral advantages over explosively-driven tools. For example, use ofthe hydraulic tools may simplify or eliminate some safety, transport,and certification concerns associated with explosively-driveninstallation tools. However, the hydraulic tools create a unique set ofchallenges for users. For example, as shown in FIG. 1, a wedgeinstallation tool 10 may include a hydraulic driver 100, aninterchangeable wedge frame 110 (also referred to as a “head”), and aram 120.

Wedge frame 110 may be a conventional tool head, such as a tool headused by manufactures for securing wedge connectors at relatively low(e.g., non-ballistic) ram velocities. Wedge frame 110 may be sized fordifferent wedge connectors (e.g., depending on the thickness of mainlineand tap electrical cables). Positioning of wedge frame 110 (e.g., tohold a wedge during installation) can be cumbersome due to the size orweight of hydraulic driver 100 and the fact that wedge frame 110 isscrewed directly to hydraulic driver 100. Particularly, hydraulic driver100 and wedge frame 110 must be maneuvered into position between themainline and tap conductor, and then rotated to snug ram 120 against thewedge prior to activation of hydraulic driver 100 to advance ram 120.

FIG. 2 provides a view of wedge installation tool 10 including adisconnect assembly 200 installed on wedge installation tool 10.According to an implementation described herein, disconnect assembly 200is provided to allow wedge frame 110 to be positioned and snug against awedge of a wedge connector prior to connecting wedge frame 110 tohydraulic driver 100. As shown in FIG. 2, disconnect assembly 200 mayinclude a head coupler 210 and a tool coupler 220. Head coupler 210 mayinclude an extension rod 212 and a threaded section 214 configured toreceive one of wedge frames 110. Two wedge frames 110 are shown in FIG.2, and either of the two wedge frames 110 may be interchangeably usedwith head coupler 210. As described further herein, tool coupler 220 mayinclude a threaded section to connect to hydraulic driver 100 and asection to secure head coupler 210 to tool coupler 220. Head coupler 210and tool coupler 220 may be generally be made from a metal alloy, suchas SAE grade 4140 steel. Extension rod 212 may be made of a corrosionresistant metal, such as stainless steel.

FIG. 3 provides a cross sectional view of an exemplary implementation ofhead coupler 210. Cross-sectional hatching is excluded from FIG. 3 forsimplicity. As shown in FIG. 3, head coupler 210 may include extensionrod 212 within a cylindrical bore 302 and threaded section 214.Cylindrical bore 302 may include a first portion 304 with a diameterconfigured to contain a spring 306 around the circumference of extensionrod 212 and to receive ram 120 from hydraulic driver 100. Cylindricalbore 302 may include a second portion 308 with a smaller diameter topermit travel of extension rod 212 within cylindrical bore 302 withminimal clearance. A shoulder 310 may be formed at the interface offirst portion 304 and second portion 308.

Extension rod 212 may include a cylindrical member to transfer forcefrom ram 120 to a wedge. Forces transferred from ram 120 may be in therange of between three to eight tons. Extension rod 212 travels axiallywithin cylindrical bore 302. Extension rod 212 may include a proximalend 312 to receive applied force from ram 120 and a distal end 314 thatmay extend out of cylindrical bore 302. Proximal end 312 may include alarge diameter portion 316 (also referred to as support rim 316) thatconforms generally (e.g., with an appropriate clearance) to the diameterof first portion 304 of cylindrical bore 302. Spring 306 may generallyencircle a portion of extension rod 212 within first portion 304 ofcylindrical bore 302. Spring 306 may provide a retention force (e.g.,axially along cylindrical bore 302) to retain extension rod 212 withincylindrical bore 302. Spring 306 may be constrained between shoulder 310of cylindrical bore 302 and support rim 316 of proximal end 312. Theaxial force of spring 306 may be much smaller than a force applied toextension rod 212 by ram 120. Upon application of force from ram 120,spring 306 may be compressed between shoulder 310 and support rim 316.Travel of extension rod 212 may be limited to the length of firstportion 304 minus the length of compressed spring 306 when compressedbetween shoulder 310 and support rim 316.

Distal end 314 may include a threaded bore 318 to accommodate an end cap320. For example, end cap 320 may be screwed into threaded bore 318. Endcap 320 may include a diameter larger than the diameter of secondportion 308 and approximately equal to an outer diameter of firstportion 304 of cylindrical bore 302. Because end cap 320 has a largerdiameter than second portion 308 of cylindrical bore 302, end cap 302may limit axial travel of extension rod 212 in a direction toward largediameter portion 316 such that the proximal end 312 does not extendbeyond the end of first portion 304 of cylindrical bore 302. An exposedsurface of end cap 320 may engage another surface (e.g., a wedge) toapply force supplied by ram 120 on proximal end 312. In anotherimplementation, end cap 320 may include a non-flat surface for to enablealternate functions for disconnect assembly 200 (e.g., functions otherthan forcing a wedge of a wedge connector). For example, in otherembodiments, end cap 320 may include a cutting edge or a crimpingsurface.

Head coupler 210 may also include multiple annular protrusions 322-1through 322-5 (also referred to herein as a “protrusion ring” orcollectively as “protrusion rings 322”) around a circumference of headcoupler 210. Protrusion rings 322 may be configured to engagecorresponding grooves (e.g., grooves 424, described below in connectionwith FIG. 4) of tool coupler 220 to restrict axial motion of headcoupler 210 with respect to tool coupler 220. Thus, protrusion rings 322may be load bearing against a reaction to a force applied by ram 120and/or extension rod 212. Although five protrusion rings 322 are shown,in other implementations, more or fewer protrusion rings 322 may beused, depending, for example, upon the expected loads applied byhydraulic driver 100. In one implementation, one or more protrusionrings 322 and corresponding grooves 424 may be of different sizes (e.g.,mechanically indexed) to prevent partial insertion or misalignment ofhead coupler 210 within tool coupler 220. For example, as shown in FIG.3, protrusion ring 322-5 may have a wider surface than any of protrusionrings 322-1 through 322-4. In one implementation, the section of headcoupler 210 encircled by protrusion rings 322 may be cylindrical toallow insertion of head coupler 210 into tool coupler 220 in anyrotational orientation around the axis of the longitudinal bore 302.

FIG. 4 provides a cross sectional view of tool coupler 220 according toan implementation described herein. Cross-sectional hatching is excludedfrom FIG. 4 for simplicity. As shown in FIG. 4, tool coupler 220 mayinclude a tool engagement section 410, a head engagement section 420,and a retention system 430. Tool engagement section 410 may include athreaded bore 412 to connect to hydraulic driver 100. Threaded bore 412may be sized to match the diameter and threads of wedge frame 110, suchthat tool coupler 220 may be threaded onto hydraulic driver 100 in placeof wedge frame 110.

Head engagement section 420 may include a U-shaped channel 422. U-shapedchannel 422 may include multiple grooves 424-1 through 424-5(referred tocollectively herein as “grooves 424”) and may be sized to receive headcoupler 210 with multiple protrusion rings 322-1 through 322-5. Grooves424 may be configured to engage corresponding protrusion rings 322 ofhead coupler 210 (e.g., when head coupler 210 is connected to toolcoupler 220) to restrict axial motion of head coupler 210 with respectto tool coupler 220. In one implementation, one or more grooves 324 andcorresponding protrusion rings 322 may be of different sizes (e.g.,mechanically indexed) to prevent partial insertion or misalignment ofhead coupler 210 within tool coupler 220. For example, as shown in FIG.3, grooves 424-5 may have a wider surface than any of grooves 424-1through 424-4.

Retention system 430 may include a mechanism to lock head coupler 210within tool coupler 220. In one implementation, a spring-loaded latch432 may allow insertion of head coupler 210 into tool coupler 220 andsnap into place over head coupler 210 after head coupler 210 is fullyinserted within tool coupler 220. Thus, retention system 430 may providean automatic or “hands-free” mechanism to secure head coupler 210 intool coupler 220 and keep cylindrical bore 302 aligned with threadedbore 412. After head coupler 210 has been inserted in tool coupler 220and spring-loaded latch 432 has snapped into a securing position, aspring-loaded pin 434 may secure spring-loaded latch 432 in place toprevent head coupler 210 from forcing off spring-loaded lever 432.Spring-loaded pin 434 may be manually disengaged from spring-loadedlever 432 to allow spring-loaded lever 432 to lift up and release headcoupler 210 from tool coupler 220. Thus, manual (e.g., operator)intervention may be required to disengage retention system 430.

In another implementation, retention system 430 may include a differentlocking system, such as one or more retention pins that may be insertedtransversely across a portion of U-shaped channel 422 after head coupler210 has been inserted within tool coupler 220. In one implementation,transversally-mounted retention pins may also be spring loaded.Generally, retention system 430 may be required to prevent head coupler210 in tool coupler 220 from separating when in an unloaded state (e.g.,when forces are not being applied by ram 120). In a loaded state, theextension of ram 120 into cylindrical bore 302 would prevent cylindricalbore 302 and threaded bore 412 form becoming misaligned.

FIG. 5 provides a cross section view of disconnect assembly 200 in acoupled configuration. As shown in FIG. 5, head coupler 210 is engagedwithin U-shaped channel 422 of tool coupler 220. U-shaped channel 422and head coupler 210 may include corresponding indexing interfaces toensure a proper connection and to prevent axial motion of head coupler210 with respect to tool coupler 220. More particularly, each of grooves424-1 through 424-5 may engage a corresponding protrusion ring 322-1through 322-5 of head coupler 210. While the indexing interfaces shownin FIG. 5 are described in the context of rings 322 on head coupler 510and grooves 424 on tool coupler 220, it other implementations, theindexing interface may include different configurations (e.g., rings ontool coupler 510 and grooves on head coupler 220). Cylindrical bore 302aligns with threaded bore 412 such that ram 120 of hydraulic driver 100(not shown in FIG. 5) may advance through first portion 304 ofcylindrical bore 302 and into second portion 308 of cylindrical bore 302to apply force to proximal end 312 of extension rod 212. Distal end 314of extension rod 212 may extend out of the second portion 308 ofcylindrical bore 302, causing end cap 320 to contact, for example, awedge connector (not shown).

FIG. 6 provides an image of disconnect assembly 200 installed betweenhydraulic driver 100 and wedge frame 110. As shown in FIG. 6,spring-loaded lever 432 of retention system 430 locks head coupler 210within U-shaped channel 422 of tool coupler 220 to prevent inadvertentdisengagement of head coupler 210 and tool coupler 220. In oneimplementation, head coupler 210 may rotate (e.g., along the common axisshared by extension rod 212 and cylindrical bore 302) within U-shapedchannel 422 of tool coupler 220. This rotation may allow, for example,simple adjustment of an orientation of wedge frame 110 when wedge frame110 is threaded onto threaded section 214 of head coupler 210. Forexample, the depth of insertion of the threaded section 214 can beadjusted (e.g., to position end cap 320 in contact a wedge connectorprior to activation of ram 120) when head coupler 210 is disconnectedfrom tool coupler 220. Additionally, the depth of insertion of thethreaded section 214 may be adjusted when head coupler is connected totool coupler 220 without requiring rotation of hydraulic driver 100.

FIG. 7 is a flowchart of an exemplary process 700 for installing a wedgeconnector using a hydraulic installation tool and a disconnect assembly,according to an implementation described herein. Process 700 isdescribed below with reference to FIGS. 8A-8C, which show isometricviews of some of installation process 700. Process 700 may includethreading a tool coupler of the disconnect assembly onto an installationtool (block 710). For example, as shown in FIG. 8B, tool coupler 220 ofdisconnect assembly 200 may be threaded onto hydraulic driver 100. Toolcoupler 220 may engage with hydraulic driver 100 such that ram 120 (notvisible in FIG. 8B) of hydraulic driver 100 will have a channel toextend through when activated. In one implementation, tool coupler 220may be threaded (and/or otherwise secured) to hydraulic driver 100 as avendor process and provided to a user as a pre-configured assembly.

Process 700 may further include threading a head coupler of a disconnectassembly onto a wedge frame (block 720) and positioning the wedge frameon a wedge connector between a main electrical line and a tap line(block 730). For example, as shown in FIG. 8A, head coupler 210 of adisconnect assembly 200 may be threaded into wedge frame 110. A wedgeconnector 810 may be positioned on a main electrical line 820 and a tapline 830. Wedge frame 110 may be positioned to engage wedge connector810. Wedge frame 110 may be selected, for example, from multiple-sizedwedge frames 110 (e.g., based on the cable size of electrical line 820and tap line 830). Head coupler 210 may be threaded further into wedgeframe 110 so that end cap 320 may engage wedge 810.

Process 700 may further include connecting the head coupler to the toolcoupler (block 740). For example, as shown in FIG. 8C, tool coupler 220may be mated with head coupler 210 to form single disconnect assembly200. Retention system 430 may snap into place to prevent inadvertentseparation of head coupler 210 from tool coupler 220.

Process 700 may also include extending a ram from the installation toolto apply force to a rod of the disconnect assembly block (750), andretracting the ram (block 760). For example, as shown in FIG. 8C, anoperator may depress activation trigger 840 of hydraulic driver 100 tocause ram 120 to extend through tool coupler 220 and engage extensionrod 212. Extension rod 212 may extend out of cylindrical bore 302forcing end cap 320 to apply a force to wedge connector 810. After wedgeconnector 810 has been forced completely into position, an operator maydepress retraction trigger 850 of hydraulic driver 100 to cause ram 120to retract out of head coupler 210 and tool coupler 220.

Process 700 may further include disconnecting the head coupler from thetool coupler (block 770), and removing the head coupler from the wedgeframe (block 780). For example, an operator may release retention system430 to allow head coupler 210 and tool coupler 220 to be disconnected.Head coupler 210 may be unscrewed from wedge frame 110 in the event headcoupler may need to be affixed to a different sized wedge frame 110 inthe future.

According to implementations described herein, a disconnect assembly isprovided to allow a wedge frame to be positioned and snug against awedge prior to connecting the wedge frame to a hydraulic driver. In oneimplementation the disconnect assembly may include a head couplerportion and a tool coupler portion. The head coupler portion may includea threaded portion on a first part of an exterior surface to connect toa wedge frame, a longitudinal bore, a rod configured to slidelongitudinally within the longitudinal bore, and a set of annularprotrusions on a second part of the exterior surface. The tool couplerportion may include a threaded bore configured to mechanically attachthe tool coupler portion to the tool, and a channel to receive a headcoupler portion. The channel may include a set of grooves correspondingto the set of annular protrusions on the head coupler portion. When thehead coupler portion is connected to the tool coupler portion, a ramfrom the hydraulic tool may engage the rod to apply force to an objectin the wedge frame.

The foregoing description of exemplary implementations providesillustration and description, but is not intended to be exhaustive or tolimit the embodiments described herein to the precise form disclosed.Modifications and variations are possible in light of the aboveteachings or may be acquired from practice of the embodiments.

Although the invention has been described in detail above, it isexpressly understood that it will be apparent to persons skilled in therelevant art that the invention may be modified without departing fromthe spirit of the invention. Various changes of form, design, orarrangement may be made to the invention without departing from thespirit and scope of the invention. Therefore, the above mentioneddescription is to be considered exemplary, rather than limiting, and thetrue scope of the invention is that defined in the following claims.

No element, act, or instruction used in the description of the presentapplication should be construed as critical or essential to theinvention unless explicitly described as such. Also, as used herein, thearticle “a” is intended to include one or more items. Further, thephrase “based on” is intended to mean “based, at least in part, on”unless explicitly stated otherwise.

What is claimed is:
 1. A disconnect assembly for a tool that drives aram into a wedge frame, the disconnect assembly comprising: a headcoupler portion, including: a threaded portion on a first part of anexterior surface to connect to the wedge frame, a longitudinal bore, arod configured to slide longitudinally within the longitudinal bore, anda set of annular protrusions on a second part of the exterior surface;and a tool coupler portion including: a threaded bore configured tomechanically attach the tool coupler portion to the tool, and a channelto receive a head coupler portion, wherein the channel includes a set ofgrooves corresponding to the set of annular protrusions on the headcoupler portion, wherein, when the head coupler portion is connected tothe tool coupler portion, the ram engages the rod to apply force to anobject in the wedge frame.
 2. The disconnect assembly of claim 1,further comprising: a retention system to retain the head couplerportion within the channel of the tool coupler portion.
 3. Thedisconnect assembly of claim 2, wherein the retention system isautomatically activated to retain the head coupler portion uponinsertion of the head coupler portion within the tool coupler portion.4. The disconnect assembly of claim 3, wherein the retention system isconfigured to require manual intervention to disengage the retentionsystem.
 5. The disconnect assembly of claim 1, wherein the head couplerportion is configured to be received by the tool coupler portion in anyrotational orientation around an axis of the longitudinal bore.
 6. Thedisconnect assembly of claim 1, wherein the set of grooves and the setof annular protrusions are mechanically indexed such that the headcoupler portion can be inserted into the tool coupler portion only in aparticular location within the channel.
 7. The disconnect assembly ofclaim 1, wherein the threaded portion of the head coupler portion isconfigured to be inserted into the wedge frame to an adjustable depth,and wherein the depth of insertion of the threaded portion can beadjusted when the head coupler portion is not connected to the toolcoupler portion.
 8. The disconnect assembly of claim 7, of previousclaim, wherein the depth of insertion of the threaded portion can beadjusted when the head coupler portion is connected to the tool couplerportion and without rotating the tool.
 9. The disconnect assembly ofclaim 1, wherein the force applied to the object in the wedge frameexceeds three tons.
 10. The disconnect assembly of claim 1, wherein thesecond part of the exterior surface of the head coupler portion issubstantially cylindrical.
 11. A system, comprising: a hydraulic drivetool including housing, a ram, and a wedge frame; and a disconnectassembly interposed between the ram and the wedge frame, the disconnectassembly comprising: a head coupler portion configured to bemechanically attached to the wedge frame, the head coupler portionincluding: a longitudinal bore, a rod configured to slide longitudinallywithin the longitudinal bore, and a first indexing interface, and a toolcoupler portion configured to be mechanically secured to the housing,the tool coupler including a channel to removeably connect the headcoupler portion to the tool coupler portion, wherein the channelincludes a second indexing interface corresponding to the first indexinginterface on the head coupler portion, wherein, when the head couplerportion is connected to the tool coupler portion, the ram engages therod to apply force to an object in the wedge frame.
 12. The system ofclaim 11, wherein the tool coupler portion includes a threaded boreconfigured to mechanically attach to the housing.
 13. The system ofclaim 11, wherein the first indexing interface includes one of: a firstset of protruding rings on an exterior surface of the head couplerportion, or a first set of grooves on the part of the exterior surfaceof the head coupler portion; and wherein the second indexing interfaceincludes one of: a second set of grooves configured to receive the firstset of protruding rings, or a second set of protruding rings configuredto receive the first set of grooves.
 14. The system of claim 11, whereinthe disconnect assembly further includes: a retention system to retainthe head coupler portion within the channel of the tool coupler portion.15. The system of claim 14, wherein the retention system isautomatically activated to retain the head coupler portion uponinsertion of the head coupler portion within the tool coupler portion,and wherein the retention system is configured to require manualintervention to disengage the retention system.
 16. The system of claim11, wherein the head coupler portion is configured to be attached to thewedge frame at an adjustable depth, and wherein the depth of attachmentis adjustable when the head coupler portion is not connected to the toolcoupler portion.
 17. The system of claim 11, wherein the depth ofattachment is configured to be adjusted when the head coupler portion isconnected to the tool coupler portion without rotating the tool.
 18. Amethod for installing a wedge connector positioned between twoconductive cables, the method comprising: connecting a head couplerportion of a disconnect assembly to a wedge frame, wherein the headcoupler portion includes an extension rod within a longitudinal bore;positioning the wedge frame and a first end of the extension rod againstthe wedge connector; connecting the head coupler portion to a toolcoupler portion of the disconnect assembly, wherein the tool couplerportion is connected to a hydraulic drive tool that includes a ram;causing the hydraulic drive tool to apply force to a second end of theextension rod, wherein applying the force to the second end causes thefirst end to apply force to the wedge connector; and disconnecting thehead coupler portion from the tool coupler portion.
 19. The method ofclaim 18, wherein causing the hydraulic drive too to apply force to thesecond end of the extension rod includes causing the ram to extend intothe longitudinal bore of the head coupler section.
 20. The method ofclaim 19, further comprising: causing the hydraulic drive tool toretract the ram from the longitudinal bore.